Hard Hat with Strap Breakaway Device

ABSTRACT

A breakaway device for use with the strap system of a hard hat. The breakaway device is coupled to a strap system of a hard hat, and the strap system is coupled to a hard hat outer shell. The breakaway device includes a housing and a releasable component mated to the housing. In specific embodiments, the breakaway device further includes a latch. The latch includes a catch. When the device is configured in an unlatched position, the catch does not interfere with the removal of the releasable component from the housing. When the device is configured in a latched position, the catch does interfere with the removal of the releasable component from the housing, increasing the magnitude of force required to release the releasable component from the housing. In specific embodiments, both configurations are achieved with a single device. In other specific embodiments, the configurations are achieved through separate devices.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application is a continuation of International Application No. PCT/US2022/080821, filed Dec. 2, 2022, which claims the benefit of and priority to U.S. Provisional Application No. 63/294,518, filed Dec. 29, 2021, U.S. Provisional Application No. 63/286,863, filed Dec. 7, 2021, each of which is incorporated herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of hard hat technology. The present invention relates specifically to breakaway devices for a hard hat strap system.

Hard hats are often used in construction or other environments/worksites where head protection is warranted. For example, hard hats are used in environments where there is a risk for head injury and act to provide added protection to a worker's head. Hard hats are also used in environments where there is a risk of a large and/or heavy object applying a high release force to the hard hat in a substantially lateral direction and/or to the underside of the hard hat.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a hard hat system including a hard hat including a shell formed from a rigid material, a plurality of female couplers coupled to the shell, a plurality of straps configured to secure the shell to the head of the wearer, a plurality of first male couplers including a first button received within the aperture of a female coupler thereby coupling the first male coupler to the female coupler, a plurality of second male couplers including a second button received within the aperture of a female coupler thereby coupling the second male coupler to the female coupler. Each second button includes a top surface facing away from the base of the respective female coupler and towards the head of the wearer. The shell includes an external surface and an internal surface that defines a cavity sized to receive the head of a wearer. Each of the plurality of female couplers includes a base and an aperture opposite the base. Each first button includes a top surface facing away from the base of the respective female coupler and towards the head of the wearer, and the first male coupler decouples from the female coupler when a first predetermined release force is applied that separates the first male coupler from the female coupler. The second male coupler decouples from the female coupler when a second predetermined release force is applied that separates the second male coupler from the female coupler, and the second predetermined release force is at least 50 Newtons greater than the first predetermined release force. Each strap of the plurality of straps is directly coupled to one of the first male couplers and one of the second male couplers, one of which detachably couples to a female coupler of the plurality of female couplers at a time, thereby coupling the respective strap to the hard hat.

Another embodiment of the invention relates to a hard hat system including a hard hat including a shell formed from a rigid material, the shell including an external surface and an internal surface that defines a cavity sized to receive the head of a wearer, a plurality of female couplers coupled to the shell, each of the plurality of female couplers including a base and an aperture opposite the base, a plurality of straps configured to secure the shell to the head of the wearer, a plurality of first male couplers including a first button received within the aperture of a female coupler thereby coupling the first male coupler to the female coupler, a plurality of second male couplers including a second button received within the aperture of a female coupler thereby coupling the second male coupler to the female coupler. Each second button includes a top surface facing away from the base of the respective female coupler and a side surface that extends from the top surface at a second obtuse angle and that circumferentially surrounds the second button. The first button includes a top surface facing away from the base of the respective female coupler, and a side surface that extends from the top surface at a first obtuse angle and that circumferentially surrounds the first button. The first male coupler decouples from the female coupler when a first predetermined release force is applied that separates the first male coupler from the female coupler. The second male coupler decouples from the female coupler when a second predetermined release force is applied that separates the second male coupler from the female coupler, and the second predetermined release force is at least 50 Newtons greater than the first predetermined release force. Each strap of the plurality of straps is directly coupled to one of the first male couplers and one of the second male couplers, one of which detachably couples to a female coupler of the plurality of female couplers at a time, thereby coupling the respective strap to the hard hat.

Another embodiment of the invention relates to a strap system configured to secure a hard hat to the head of a wearer. The strap system includes a plurality of straps, a plurality of first male couplers including a first button received within an aperture of a female coupler coupled to a hard hat, thereby coupling the first male coupler to the female coupler, each first button including a top surface projected through the aperture of the female coupler and towards the head of the wearer and a side surface that extends from the top surface at a first obtuse angle and that circumferentially surrounds the first button, a plurality of second male couplers including a second button received within the aperture of a female coupler thereby coupling the second male coupler to the female coupler. Each second button includes a top surface facing towards the head of the wearer and a side surface that extends from the top surface at a second obtuse angle and that circumferentially surrounds the second button. Each first button includes a top surface projected through the aperture of the female coupler and towards the head of the wearer and a side surface that extends from the top surface at a first obtuse angle and that circumferentially surrounds the first button. The first male coupler decouples from the female coupler when a first predetermined release force is applied that separates the first male coupler from the female coupler. Each second button includes a top surface facing towards the head of the wearer and a side surface that extends from the top surface at a second obtuse angle and that circumferentially surrounds the second button. The second male coupler decouples from the female coupler when a second predetermined release force is applied that separates the second male coupler from the female coupler. The second predetermined release force is at least 50 Newtons greater than the first predetermined release force. Each strap of the plurality of straps is directly coupled to one of the first male couplers and one of the second male couplers, one of which couples to a female coupler of the plurality of female couplers at a time, thereby coupling the respective strap to the hard hat.

Another embodiment of the invention relates to a hard hat having an outer shell and a strap system coupled to the outer shell. The strap system includes an upper strap, a lower strap, and a breakaway device. The breakaway device includes a cover coupled to a housing. A releasable component is mated to the housing. A first aperture is formed in the housing. The upper strap is coupled between the outer shell and the first aperture. A second aperture is formed in the releasable component. The lower strap is coupled between the second aperture and the outer shell. The lower strap is configured to pass underneath the user's chin when worn. The breakaway device further includes a releasable component mated to the housing. The housing defines a pair of downwardly sloping ledges. The releasable component includes a pair of mating prongs that respectively mate to the pair of downwardly sloping ledges. When a predetermined release force is applied to the upper and lower straps across the breakaway device, the pair of mating prongs are configured to draw toward one another and release from the respective pair of mating ledges, allowing the releasable component to separate from the housing.

In certain specific embodiments, the predetermined release force is between 150 Newtons and 250 Newtons.

In another specific embodiment, a hard hat includes an outer shell, an upper strap, a lower strap, and a breakaway device. The upper strap couples the breakaway device to the outer shell at a first outer shell location, and the lower strap couples the breakaway device to the outer shell at a second outer shell location. The lower strap is configured to pass underneath the user's chin when worn. The breakaway device includes a cover coupled to a housing. A releasable component is mated to the housing. The housing defines a cavity. An interior wall defines a perimeter of the cavity. A first downwardly sloping ledge forms a first portion of the interior wall. A second downwardly sloping ledge forms a second portion of the interior wall, opposite the first downwardly sloping ledge. The releasable component includes a first prong and a second prong. The first prong mates with the first downwardly sloping ledge and the second prong mates with the second downwardly sloping ledge. When a predetermined release force is applied to the upper and lower straps across the breakaway device, the first prong is configured to release from the first ledge and the second prong is configured to release from the second ledge such that upper and lower straps separate from each other.

In certain specific embodiments, the predetermined release force is between 150 Newtons and 250 Newtons. In other specific embodiments, the cover is a latching mechanism. A catch extends from an interior surface of the cover towards the housing. The housing forms a housing channel that receives the catch. The releasable component forms a releasable component channel that aligns with the housing channel. The catch is pivotable from an unlatched position to a latched position. In the unlatched position, the catch is positioned substantially within the housing channel. In the latched position, the catch is pivoted at least in part into the releasable component channel. In certain specific embodiments, the upper strap is a first upper strap and the lower strap is coupled to the outer shell by a second upper strap. In certain specific embodiments, the lower strap includes a user-actuated buckle spaced apart from the breakaway device.

In another specific embodiment, a hard hat includes an outer shell, a breakaway device, and a strap. The breakaway device has a releasable component that mates with a receiving port. The receiving port is coupled to the outer shell. The releasable component includes a base, and the strap is coupled to the base. An arm extends from the base. A button having a button perimeter is coupled to the arm. The button defines a chamfered edge around the button perimeter. The receiving port forms an opening defined by an outer edge. The chamfered edge of the button mates with the outer edge. When a force greater than or equal to a predetermined release force is applied to the strap and the outer shell across the breakaway device, the button is configured to release from the outer edge such that the strap separates from the outer shell.

In certain specific embodiments, the predetermined release force is between 150 Newtons and 250 Newtons. In other specific embodiments, the hard hat has an interior surface and an exterior surface, and the receiving port is coupled to the interior surface. In a more specific embodiment, the receiving port is integrally formed with the interior surface. In other specific embodiments, the receiving port is coupled directly to the interior surface such that there is no length of chin strap or strap material between the hard hat interior and the receiving port. In further specific embodiments, the button is circular, and the outer edge is an annular outer edge.

Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited.

Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1A is a perspective view from the left of a hard hat with a strap breakaway device, according to an exemplary embodiment.

FIG. 1B is a top view of a hard hat strap system, according to another exemplary embodiment.

FIG. 2 is a perspective view from the front of a hard hat strap breakaway device, according to another exemplary embodiment.

FIG. 3 is a perspective view from the rear of the hard hat breakaway device of FIG. 2 , according to an exemplary embodiment.

FIG. 4 is a perspective view from the front of the hard hat breakaway device of FIG. 2 with the cover removed, according to an exemplary embodiment.

FIG. 5 is a perspective view from the rear of the hard hat breakaway device of FIG. 2 with the housing removed, according to an exemplary embodiment.

FIG. 6 is another perspective view from the rear of the hard hat breakaway device of FIG. 2 with the housing removed, according to an exemplary embodiment.

FIG. 7 is a front view of the housing of the hard hat breakaway device of FIG. 2 , according to an exemplary embodiment.

FIG. 8 is a front view of the hard hat breakaway device of FIG. 2 with the cover removed, according to an exemplary embodiment.

FIG. 9 is another front view of the hard hat breakaway device of FIG. 2 with the cover removed, according to an exemplary embodiment.

FIG. 10 is a perspective view from the front of a hard hat breakaway device, according to another exemplary embodiment.

FIG. 11 is a perspective view from the rear of the hard hat breakaway device of FIG. 10 , according to an exemplary embodiment.

FIG. 12 is a perspective view from the front of the hard hat breakaway device of FIG. 10 with the cover removed, according to an exemplary embodiment.

FIG. 13 is a perspective view from the rear of the hard hat breakaway device of FIG. 10 with the housing removed, according to an exemplary embodiment.

FIG. 14 is another perspective view from the rear of the hard hat breakaway device of FIG. 10 with the housing removed, according to an exemplary embodiment.

FIG. 15 is a front view of the housing of the hard hat breakaway device of FIG. 10 , according to an exemplary embodiment.

FIG. 16 is a front view of the hard hat breakaway device of FIG. 10 with the cover removed, according to an exemplary embodiment.

FIG. 17 is a front view of a hard hat breakaway device with the cover removed, according to another exemplary embodiment.

FIG. 18 is a rear view of the cover of the hard hat breakaway device of FIG. 17 , according to an exemplary embodiment.

FIG. 19 is a perspective view from below of a hard hat with a breakaway device, according to another exemplary embodiment.

FIG. 20 is a perspective view of a receiving port of a strap breakaway device coupled to an outer shell of a hard hat, according to an exemplary embodiment.

FIG. 21 is a side view of a releasable component of a strap breakaway device, according to an exemplary embodiment.

FIG. 22 is a perspective view from the rear of the releasable component shown in FIG. 21 , according to an exemplary embodiment.

FIG. 23 is a perspective view from the front of the releasable component shown in FIG. 21 , according to an exemplary embodiment.

FIG. 24 is a side view of the hard hat of FIG. 19 and a strap system that includes the receiving port of FIG. 20 and the releasable component of FIG. 21 , according to an exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a breakaway device for use with the strap system of a hard hat or helmet are shown. The breakaway device is configured to release when a release force is applied to the hard hat straps coupled to the device. The release of the breakaway device allows the strap system to release from the user's head in the event that a large or heavy object moving at or near head level catches the side or underside of the hard hat outer shell in a direction that promotes removal of the hard hat from the user's head.

In various embodiments, the breakaway device is positioned within the strap system of the hard hat or coupled directly to the hard hat outer shell. In specific embodiments, the breakaway device includes at least two separable components. When a force greater than or equal to a first predetermined force is applied to the upper and lower straps, or to a strap and to the outer shell, across the breakaway device, the separable components will separate from one another, releasing the strap system from the user's head. In certain specific embodiment (see FIGS. 17-18 and FIGS. 19-23 ), Applicant has design a nonswitchable breakaway mechanism for a hard hat strap. Applicant believes that this design provides a reliable release mechanism without the mechanical complexity of moving parts and switches present in other designs. In such embodiments, a user can swap out a hardhat strap that includes the breakaway mechanism for a standard strap without a breakaway mechanism if the user does not need/want the breakaway functionality (for instance, if a user is operating at an elevated height where risk of ground impact from falling is a concern and there is a low risk of large or heavy objects moving near to the user's head). Alternatively, the user can swap out the breakaway device or a component of the breakaway device to transition from the low force configuration to the high force configuration.

In other embodiments discussed herein, the breakaway mechanism has a switch or latch that allows the user to select whether the breakaway mechanism is in a low force configuration or high force configuration. In such designs, Applicant has designed respective release mechanisms that are believed to be easy to use and operationally reliable.

Referring to FIG. 1A, an operator is shown wearing a helmet or hard hat 10. As will be described, in various embodiments, the hard hat includes an outer shell 12 and a harness or strap system 14 that is coupled to the outer shell 12. Strap system 14 secures the outer shell 12 to the user's head. FIG. 1B shows strap system 14 in greater detail. Referring to FIG. 1A-1B, the strap system 14 includes an upper strap 16 that is coupled to the outer shell 12 and to a lower strap 18. The upper strap 16 is coupled to the lower strap 18 by a breakaway device, shown as breakaway device 20. As shown in FIG. 1A, upper strap 16 passes through one or more upper apertures 22 formed in breakaway device 20, and lower strap 18 passes through one or more lower apertures 26 of breakaway device 20. Lower strap 18 is additionally coupled to a female buckle component 24 of a standard strap buckle.

The perspective view shown in FIG. 1A is from the left, showing namely the right side of hard hat 10. The left side of outer shell 12 (not shown) is substantially the same as the right side of outer shell 12. Referring to FIG. 1B, upper strap 17 couples to the left side of the outer shell (not shown). Upper strap 17 is coupled to lower strap 19 by a standard strap connector 21 that does not include components configured to separate or release under a designated or predetermined applied force to the strap system 14. Lower strap 19 is additionally coupled to a male buckle component 25 of a standard strap buckle. The female buckle component 24 and male buckle component 25 releasably mate to secure the outer shell 12 to the user's head. As such, lower straps 18 and 19 together form a standard hardhat chin strap. The chinstrap buckle formed by female buckle component 24 and male buckle component 25 allows the user to manually release the strap system 14 when the user decides to remove the hard hat 10 at the end of use. As such, the user may remove the hard hat 10 at the end of use without releasing or otherwise actuating the breakaway device 20.

In some specific embodiments, a breakaway device, such as breakaway device 20, is positioned on the right side of the strap system, rather than on the left side, and a standard connector, such as connector 21, is positioned on the left side of the strap system, rather than the right side. In other specific embodiments, a breakaway device 20 is positioned on both the left side of the hard hat and the right side of the hard hat, and no standard connector 21 is utilized.

Referring to FIG. 1A, when a release force is applied to the strap system 14, the straps system 14 is pulled taught around the underside of the user's head. As such, the upper strap 16 and lower strap 18 apply opposing forces to upper apertures 22 and lower aperture 26, respectively. As will be described in greater detail below, an application of a release force to the strap system 14 that is greater than or equal to the predetermined release force generates a release of two or more separable components of breakaway device 20. As such, breakaway device 20 allows hard hat 10 to be safely removed from the user's head under a release force application greater than or equal to the predetermined release force.

Referring to FIGS. 2-9 , various views of a breakaway device 120 are shown. Breakaway device 120 is similar to breakaway device 20, except for the differences described herein. Referring to FIGS. 2-3 , breakaway device 120 includes a cover 130 coupled to a housing 132. The cover 130 defines one or more upper apertures, specifically two upper apertures 122. Upper apertures 122 correspond to one or more upper apertures, specifically two upper apertures 123, defined in the housing 132. The upper apertures 122, 123 are sized and configured to receive one or more upper straps of a hard hat strap system as described above. Breakaway device 120 also includes a latch or latching component 134 and a releasable component 136, which will be described in greater detail below. A lower aperture 126 is defined in the releasable component 136. The lower aperture 126 is sized and configured to receive a lower strap of a hard hat strap system, as described above.

Referring to FIG. 4 , the breakaway device 120 is shown with the cover 130 decoupled and removed from the housing 132. A cavity 138 is formed in the housing 132. A portion of the latch 134 and a portion of the releasable component 136 are positioned within the cavity 138. An interior wall 139 defines a perimeter of the cavity 138. The releasable component 136 mates with at least a portion of the interior wall 139. The cavity 138 is sized to allow the latch 134 to pivot within the cavity 138, specifically to pivot between a latched and an unlatched position with respect to releasable component 136, as will be described in greater detail below. The housing 132 additionally defines indents 140 and 142. Upon assembly of the breakaway device 120, protrusions 144 and 146 of cover 130 (shown in FIGS. 5-6 ) mate with indents 140 and 142, respectively, to, in combination with grips 150, securely couple cover 130 to housing 132, thus forming the breakaway device 120 shown in FIGS. 2 and 3 .

Referring to FIGS. 5-6 , the breakaway device 120 is shown with the housing 132 decoupled and removed from the cover 130. The latch 134 includes a body 148 that is pivotably coupled to cover 130 by grips 150. As shown in FIGS. 5-6 , body 148 is annular, and grips 150 are substantially L-shaped. Grips 150 extend through the interior of annular body 148 and, when the breakaway device 120 is assembled (as shown in FIG. 3 ), engage a ledge 131 of housing 132. The grips 150 allow axial rotation or pivoting of body 148 but restrict substantial translation of body 148 with respect to cover 130 and housing 132.

A handle 154 extends radially from latch body 148. During use, a user, specifically the finger or thumb of a user, actuates handle 154 to pivot latch 134 between an unlatched position (FIG. 5 ) and a latched position (FIG. 6 ), with respect to releasable component 136. A latch arm 156 also extends radially from latch body 148. The latch arm 156 is spaced apart from the handle 154. A catch 158 protrudes from the latch arm 156, extending away from the cover 130. Referring to releasable component 136, a pair of mating prongs 160 extend from a base 162. A reinforcement prong 164 also extends from base 162 in the direction of latch 134. A projection 166 extends from reinforcement prong 164 toward the cover 130. Reinforcement prong 164 is further offset from cover 130 than mating prongs 160 where reinforcement prong 164 and mating prongs 160 respectively extend from base 162.

FIG. 5 shows a first configuration of breakaway device 120. In this configuration, the latch 134 is in an unlatched position with respect to releasable component 136. In the unlatched positioned, latch 134 does not interfere with the release of releasable component 136 from the reminder of breakaway device 120. In the first configuration, releasable component 136 is released, removed, or separated from housing 132 under the application of a release force greater than or equal to a first predetermined release force. In specific embodiments, the first predetermined release force is set by the EN397 standard, specifically, the first predetermined force is between 150 Newtons and 250 Newtons.

FIG. 6 shows a second configuration of breakaway device 120. In this configuration, the latch 134 has been pivoted to a latched position with respect to releasable component 136. In the latched position, latch 134 interferes with the release of releasable component 136 under application of a release force, as described above. Specifically, in the latched position, catch 158 of latch 134 is positioned at least in part beneath projection 166, such that an upper surface 168 of catch 158 engages a lower surface 170 of projection 166 during application of the release force. The interference provided by catch 158 in the latched position increases the magnitude of release force required to release the releasable component 136 from the housing 132. As such, in the second configuration, the releasable component is released, removed, or separated from the housing 132 under the application of a release force greater than or equal to a second predetermined release force that is greater than the first predetermined release force. In specific embodiments, the second predetermined release force is set by the EN12492 standard, specifically the second predetermined force is greater than or equal to 500 Newtons.

In specific embodiments, prior to the application of a release force, when breakaway device 120 is in a neutral position, lower surface 170 is positioned above upper surface 168, and there is no physical contact between lower surface 170 and upper surface 168. Lower surface 170 is then brought into contact with upper surface 168 upon application of the release force to the hard hat. In other specific embodiments, lower surface 170 rests against upper surface 168, and thus, lower surface 170 and upper surface 168 do physically contact one another in the neutral position, prior to the application of a release force to the hard hat.

Applicant has found environments where users are operating at elevated heights, such as scaffolding projects or climbing-related adventure sports, to require a device configuration with a higher predetermined release force, such as the second configuration described above. This allows the hard hat to remain protectively attached to a user's head when ground impact forces from a fall are applied to the hard hat. Alternatively, Applicant has found environments where users are surrounded by a significant volume of large and/or heavy airborne objects at or near head level, such as certain warehouse environments, to require a device configuration with a lower predetermined release force, such as the first configuration described above. This allows the hard hat to be more readily released prior to strangling a user if an object moving at head height catches the side or underside of the hard hat. Breakaway device 120 allows a user to readily switch between first and second safety configurations as safety conditions change.

Referring to FIGS. 7-9 , housing 132 is shown in greater detail. In FIG. 7 , a support indentation 172 is shown, formed within cavity 138. Referring to FIGS. 8-9 , support indentation 172 receives reinforcement prong 164 and secures reinforcement prong 164 against substantial flexure in the left and/or right direction. Specifically, in the second configuration (FIG. 9 ), when the latch 134 is in a latched position, support indentation 172 secures reinforcement prong 164 against flexure significant enough to draw projection 166 substantially out of alignment with catch 158.

Referring again to FIG. 7 , mating ledges 174 form a portion of interior wall 139 of cavity 138. Mating ledges 174 are angled in a downward sloping direction toward respective mating segments 176 of interior wall 139. An angle 178 is defined between each corresponding mating ledge 174 and mating segment 176. In specific embodiments, angle 178 ranges from 120 degrees to 130 degrees. Mating ledge 174 and mating segment 176 substantially complement the exterior side of mating prong 160. FIGS. 8-9 show releasable component 136 mated to housing 132. Mating prongs 160 of releasable component 136 include mating projections 180 that each define a projection angle 182 with the remainder of the respective mating prong 160. Projection angle 182 is substantially the same as angle 178. As such, mating projections 180 substantially complement the respective mating ledges 174 and mate the releasable component 136 to the housing 132.

Referring to FIG. 8 , the first, lower release force, configuration of breakaway device 120 is shown. When latch 134 is in the unlatched position, the mating projections 180 remain mated to the respective mating ledges 174 until a force greater than or equal to the first predetermined release force is applied to the hard hat. Once the applied release force meets or exceeds the first predetermined release force, mating prongs 160 begin to flex inwardly toward one another. The inward flexure of mating prongs 160 withdraws the mating projections 180 from the respective mating ledges 174, allowing releasable component 136 to be released from housing 132.

Referring to FIG. 9 , the second, higher release force, configuration is shown. When the latch 134 is pivoted to the latched position, latch 134 provides interference against the release of the releasable component. The described interference increases the magnitude of release force required to generate the release of releasable component 136 from housing 132. Specifically, in the second configuration, a higher magnitude of force is required to begin drawing the mating prongs 160 toward one another, and mating projections 166 remain mated to the respective mating ledges 174 until a higher magnitude of force, specifically the second predetermined force, is applied to the hard hat.

Referring to FIGS. 10-16 , various views of a breakaway device 220 are shown. Breakaway device 220 is similar to breakaway devices 20 and 120, except for the differences described herein. Referring to FIGS. 10-11 , breakaway device 220 includes a latch or latch cover 234 coupled to a housing 232. The housing 232 defines one or more upper apertures, specifically two upper apertures 222. The upper apertures 222 are sized and configured to receive one or more upper straps of a hard hat strap system as described above. Breakaway device 220 also includes a releasable component 236 that mates with housing 232, as will be described in greater detail below. A lower aperture 226 is defined in the releasable component 236. The lower aperture 226 is sized and configured to receive a lower strap of a hard hat strap system, as described above. In other embodiments, the breakaway device 220 is oriented 180 degrees from the orientation of the embodiment shown. In such embodiments, aperture 226 is an upper aperture sized and configured to receive an upper strap or straps of a hard hat strap system, while the apertures 222 are lower apertures sized and configured to receive a lower strap or straps of a hard hat strap system.

The latch cover 234 is pivotably coupled to housing 232 by flanges 250. Flanges 250 protrude inwardly from an outer wall 233 of housing 232. Flanges 250 extend over and engage an exterior surface 252 of latch cover 234. The engagement of flanges 250 with exterior surface 252 permits axial rotation or pivoting of latch cover 234 but restricts substantial translation of latch cover 234 with respect to housing 232. Additionally, a handle 254 protrudes from exterior surface 252 of latch cover 234. During use, a user, specifically the finger or thumb of a user, actuates handle 254 to pivot latch cover 234 between an unlatched position (FIG. 13 ) and a latched position (FIG. 14 ), with respect to releasable component 236.

Referring to FIG. 12 , the breakaway device 220 is shown with the latch cover 234 decoupled and removed from the housing 232. A cavity 238 is formed in the housing 232. A portion of the releasable component 236 is positioned within the cavity 238. An interior wall 239 defines a perimeter of the cavity 238. The releasable component 236 mates with at least a portion of the interior wall 239. Specifically, a pair of mating prongs 260 extend from a base 262 of releasable component 236, and mating prongs 260 mate with interior wall 239, as will be described in more detail below.

A channel 290 is additionally formed within the housing 232. Upon assembly of breakaway device 220, channel 290 receives catch 258 (shown in FIGS. 13-14 ) of latch cover 234. Additionally, one or more channels 292 are formed in and pass through one or more portions of breakaway device 220. As shown in FIG. 12 , channels 292 are formed in and pass through each of the mating prongs 260. Channels 292 respectively align with channel 290, such that channels 292 can respectively receive catch 258 when catch 258 is rotated from a latched position (FIG. 13 ) to an unlatched position (FIG. 14 ).

FIGS. 13-14 show the breakaway device 220 with the housing decoupled and removed from the latch cover 234. A catch 258 protrudes from an interior surface 253 of latch cover 234. In specific embodiments, catch 258 is a rib that is integrally formed with latch cover 234. As shown in FIGS. 13-14 , catch 258 extends for an arc length of greater than 180 degrees and less than 360 degrees. When breakaway device 220 is assembled, catch 258 is received by channel 290 (shown in FIG. 12 ) and, in addition, by channels 292 when latch 234 is in a latched position. In other specific embodiments, catch 258 may be a discrete component that is coupled to interior surface 253.

FIG. 13 shows a first configuration of breakaway device 220. In this configuration, the latch 234 is in an unlatched position with respect to releasable component 236. Specifically, catch 258 is removed from and not received by or positioned within either of channels 292 of breakaway device 220. As such, catch 258 does not interfere with the release of releasable component 236 from the housing 232. In the first configuration, releasable component 236 is released, removed, or separated from the housing 232 under the application of a release force greater than or equal to the first predetermined release force.

FIG. 14 shows a second configuration of breakaway device 220. In this configuration, the latch 234 has been pivoted to a latched position with respect to releasable component 236. In the latched position, latch 234 interferes with the release of releasable component 236 under application of a release force, as described above. Specifically, in the latched position, catch 258 passes through at least a portion of each of the channels 292 of mating prongs 260. During application of the release force, an interior surface 268 of catch 258 engages a respective lower surface 270 of each channel 292. The interference provided by catch 258 in the latched position increases the magnitude of release force required to release the releasable component 236 from the housing 232. As such, in the second configuration, the releasable component is released, removed, or separated from the housing 232 under the application of a release force greater than or equal to the second predetermined release force, which is greater than the first predetermined release force.

Referring to FIG. 15 , housing 232 is shown in greater detail. Mating ledges 274 form a portion of interior wall 239 of cavity 238. Mating ledges 274 are angled in a downward sloping direction toward respective mating segments 276 of interior wall 239. An angle 278 is defined between each corresponding mating ledge 274 and mating segment 276. In specific embodiments, angle 178 ranges from 105 degrees to 130 degrees. Mating ledge 274 and mating segment 276 substantially complement the exterior side of mating prong 260. Referring to FIG. 16 , releasable component 236 is shown mated to housing 232. Mating prongs 260 of releasable component 236 include mating projections 280 that each define a projection angle 282 with the remainder of the respective mating prong 260. Projection angle 282 is substantially the same as angle 278. As such, mating projections 280 substantially complement the respective mating ledges 274 and mate the releasable component 236 to the housing 232.

The mating projections 180 remain mated to the respective mating ledges 174 until a force greater than or equal to the predetermined release force (specifically the first predetermined release force in the first configuration and the second predetermined release force in the second configuration) is applied to the hard hat. Once the applied release force meets or exceeds the predetermined release force, mating prongs 260 begin to flex inwardly toward one another. The inward flexure of mating prongs 260 withdraws the mating projections 280 from the respective mating ledges 274, allowing releasable component 236 to be released from housing 232.

In various embodiments, such as breakaway device 120 and breakaway device 220, the first and second configurations described above are achieved by a single breakaway device. In other specific embodiments, the first and second configurations are achieved by two separate breakaway devices. Such embodiments may benefit a user who, for example, utilizes one configuration significantly more often than the other and may prefer a simpler breakaway device with fewer mechanical parts, particularly if such device is readily swappable for an alternate breakaway device that offers the alternate configuration.

In certain specific embodiments, a first strap system is coupled to the outer shell of the hard hat. The first strap system includes a first breakaway device that operates in the first, lower release force, configuration. When the user alternatively desires to use a breakaway device that operates in the second, higher release force, configuration, the user decouples the first strap system from the hard hat outer shell and couples a second strap system to the outer shell. The second strap system includes a second breakaway device that operates in the second, higher release force, configuration. In other specific embodiments, the first breakaway device is decoupled from the upper and lower straps, respectively, of a given strap system, and the second breakaway device is then coupled to the same respective upper and lower straps of the given strap system.

FIGS. 17-18 show various components of an embodiment of a breakaway device that is configured to operate in the first, lower release force, configuration. The low-force breakaway device shown in FIGS. 17-18 is substantially the same as breakaway device 220 with substantially the same parts the perform substantially the same functions, except for the differences described herein.

Referring to FIG. 18 , cover 334 is substantially the same as cover 234 except that cover 334 is not a latch mechanism. Specifically, there is no catch protruding from or coupled to interior surface 353. Likewise, referring to FIG. 17 , housing 332 is substantially the same as housing 232 except that no channel 290 is defined for receiving a catch. Similarly, releasable component 336 is substantially the same as releasable component 236 except that no channels 292 are defined for receiving a catch. As such, releasable component 336 releases from the housing 332 in the same manner that releasable component 236 releases from the housing 232 when breakaway device 220 is configured in the first configuration (as described in greater detail above). As the low-force breakaway device does not include a latching mechanism, the low-force breakaway device does not transition to a second, higher force, configuration. As such, the low-force breakaway device is less mechanically complex, specifically includes fewer moving parts, compared to the latching breakaway devices 120 and 220 described above.

Should a user desire to operate without the breakaway functionality, for example, if operating at an elevated height where the risk of falling outweighs the risk of the hard hat being caught by an object moving at or near head level, the user can exchange the strap system containing the low-force breakaway device for a strap system that does not include the low-force breakaway device, such as a strap system includes two standard connectors, such as standard connector 21 (FIG. 1B), one positioned on each respective side of the hard hat. Alternatively, the user can exchange the low-force breakaway device for a standard connector 21 (FIG. 1B), specifically, can decouple the low-force breakaway device from the respective upper and lower straps coupled to the low-force breakaway device, and couple a standard connector to the same respective upper and lower straps.

Referring to FIG. 19 , a non-adjustable breakaway device, shown as low-force breakaway device 420, is depicted coupled directly to an outer shell 412 of a hard hat 410. In contrast to some of the other breakaway devices discussed herein, device 420 provides a pre-set or predetermined breakaway force and does not include a switching component that allows for force adjustment by the user. The outer shell 412 has an internal surface 413 and an external surface 415. In specific embodiments, the breakaway device 420 is coupled to the internal surface 413. A strap 414 is coupled to the breakaway device 420. When a force greater than or equal to a predetermined release force is applied to the strap 414 and the outer shell 412, across the breakaway device 420, the breakaway device is configured to release, such that the strap 414 releases from the outer shell 412. In specific embodiments, the predetermined release force is set by the EN397 standard, specifically, the predetermined force is between 150 Newtons and 250 Newtons.

Referring to FIG. 20 , a female coupler, shown as receiving port 432, of a breakaway device is shown coupled to the internal surface 413 of the hard hat outer shell 412. In specific embodiments, one or more of the receiving ports 432 (e.g., all of the plurality of receiving ports 432) are integrally formed with the outer shell 412 and protrudes into the interior of the outer shell 412. In various such embodiments, two components being integrally formed means that the two components are formed from single, integral, continuous, contiguous piece of material, such as a molded polymer material. For example, in various embodiments, the receiving port(s) 432 and the hard hat outer shell 412 are integrally formed such that the receiving port(s) 432 and the hard hat outer shell 412 are formed from single, integral, continuous, contiguous piece of material, such as a molded polymer material. The receiving port 432 forms an aperture 438 defined by an outer edge 439. In specific embodiments, the outer edge 439 is an annular outer edge.

Referring to FIGS. 21-23 , a male coupler, shown as releasable component 436, is shown. Releasable component 436 is configured to releasably mate with receiving port 432, shown in FIG. 20 . Releasable component 436 includes a base 462 that defines an opening 426 configure to receive a hard hat harness or chin strap such as strap 414, shown in FIG. 19 . And arm 464 extends from the base 462, and a button 466 is coupled to the arm 464. A side surface 474 is defined around the perimeter of the button 466. In specific embodiments, the side surface 474 forms an obtuse angle 490 with the arm 464 (see FIG. 21 ). When the releasable component 436 is mated to the receiving port 432, the side surface 474 mates with the outer edge 439. When a force greater than or equal to the predetermined release force is applied across the mated breakaway device, the button 466 is configured to release from the outer edge 439 such that the releasable component 436 separates from the receiving port 432. In specific embodiments, the button 466 is circular.

In various embodiments, when the releasable component 436 is mated to the receiving port 432, the button 466 protrudes through the aperture 438 towards the interior of the outer shell 412. Applicant has found this orientation to aid in sliding the releasable component into and out of the receiving port 432 when the receiving port is coupled to the interior of the outer shell 412 (as shown in FIG. 19 ). Applicant has also found the chamfer of the side surface 474 to aid in the insertion and release of the releasable component 436 from the receiving port 432 as described above.

Referring to FIG. 24 , in various embodiments hard hat system 408 includes a hard hat, such as hard hat 410, and a plurality of female couplers, shown as ports 432 coupled to the hard hat. In various embodiments, hard hat system 408 includes a strap system 510, which includes a plurality of straps 512 with a plurality of first male couplers, shown as releasable components 436, and a plurality of second male couplers, shown as releasable components 520, coupled to the straps 512. Strap system 510, via straps 512, is configured to secure the shell 412 to the head of the wearer. In various embodiments, each strap 512 of the plurality of straps 512 is directly coupled to one of the first releasable components 436 and one of the second releasable components 520, one of which (e.g., either first releasable components 436 or second releasable components 520) detachably couples to a female coupler (e.g., port 432) of the plurality of female couplers at a time, thereby coupling the respective strap 512 to the hard hat 410.

Hard hat 410 includes a shell 412 formed from a rigid material, and the shell 412 includes an external surface 415 and an internal surface 413 that defines a cavity 422 sized to receive the head of a wearer. In various embodiments, each of the ports 432 (e.g., female couplers) are coupled to the shell 412 (e.g., such as being integrally molded with the shell), and each of the ports 432 includes a base 434 and an aperture 438 opposite the base 434.

Referring to FIGS. 20-24 , a plurality of first male couplers, shown as releasable components 436, include a first button 466 received within the aperture of a female coupler, which thereby couples the releasable components 436 to the female coupler. In various embodiments, each first button 466 includes a top surface 472 facing away from the base 434 of the respective female coupler and towards the head of the wearer, and a side surface 474 that extends from the top surface 472 at a first obtuse angle 492, the side surface 474 circumferentially surrounding the first button 466. In various embodiments, the first releasable component 436 decouples from a female coupler (e.g., port 432) when a first predetermined release force is applied that separates the first male coupler from the female coupler.

In various embodiments, for each of the plurality of first releasable components 436, first button 466 extends from a first arm 464 that biases the first button 466 through the aperture 438 of port 432 when the first releasable component 436 is coupled to the respective port 432. Similarly, for each of the plurality of second male couplers 520 the second button extends from a second arm that biases the second button through the aperture of port 432 when the second releasable component 520 is coupled to the respective female coupler.

With reference to FIG. 24 , a plurality of second male couplers, shown as second releasable components 520, are coupled to straps 512 as well. Second releasable components 520 are functionally and structurally the same or similar to first releasable components 436 except as otherwise noted. In particular, second releasable components 520 decouple from a female coupler (e.g., port 432) when a second predetermined release force is applied that separates the first male coupler from the female coupler. In various embodiments, the second predetermined release force is at least 50 Newtons greater than the first predetermined release force, and more specifically at least 150 Newtons greater, and more specifically at least 250 Newtons greater.

In various embodiments, first releasable components 436 are colored a first color and second releasable components 520 are colored a second color different than the first color. This differential coloring scheme permits the user to quickly select the appropriate color for their work environment at the time, and it also permits other individuals to quickly inspect which coupler(s) are connected and thereby determine whether the wearer has selected the correct couplers that correspond to the current working environment.

In various embodiments, apertures 438 of the plurality of female couplers (e.g., ports 432) define a circular shape that receives the first buttons 466 (of first releasable components 436) and the second buttons (of second releasable components 520). In various embodiments, the first buttons 466 of the plurality of first male couplers (e.g., first releasable components 436) define a circular shape that is received in one of the apertures of the female couplers (e.g., ports 432). In various embodiments, the second buttons of the plurality of second male couplers (e.g., second releasable components 520) define a circular shape that is received in one of the apertures of the female couplers (e.g., ports 432).

In various embodiments, the plurality of ports 432 coupled to shell 412 include at least four ports 432. In various embodiments, the plurality of first releasable components 436 include at least four first releasable components 436, and the plurality of second releasable components 520 include at least four second releasable components 520. In various embodiments, there are twice as many first releasable components 436 coupled to the straps 512 as ports 432 coupled to the shell 412, and are twice as many second releasable components 520 coupled to the straps 512 as ports 432 are coupled to the shell 412.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. In addition, as used herein, the article “a” is intended to include one or more component or element and is not intended to be construed as meaning only one.

Various embodiments of the invention relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above. 

What is claimed is:
 1. A hard hat system comprising: a hard hat comprising a shell formed from a rigid material, the shell comprising an external surface and an internal surface that defines a cavity sized to receive the head of a wearer; a plurality of female couplers coupled to the shell, each of the plurality of female couplers comprising a base and an aperture opposite the base; a plurality of straps configured to secure the shell to the head of the wearer; a plurality of first male couplers including a first button received within the aperture of a female coupler thereby coupling the first male coupler to the female coupler, each first button comprising a top surface facing away from the base of the respective female coupler and towards the head of the wearer, wherein the first male coupler decouples from the female coupler when a first predetermined release force is applied that separates the first male coupler from the female coupler; and a plurality of second male couplers including a second button received within the aperture of a female coupler thereby coupling the second male coupler to the female coupler, each second button including a top surface facing away from the base of the respective female coupler and towards the head of the wearer, wherein the second male coupler decouples from the female coupler when a second predetermined release force is applied that separates the second male coupler from the female coupler, wherein the second predetermined release force is at least 50 Newtons greater than the first predetermined release force; wherein each strap of the plurality of straps is directly coupled to one of the first male couplers and one of the second male couplers, one of which detachably couples to a female coupler of the plurality of female couplers at a time, thereby coupling the respective strap to the hard hat.
 2. The hard hat system of claim 1, wherein the plurality of female couplers are integrally molded with the shell.
 3. The hard hat system of claim 1, wherein the apertures of the plurality of female couplers define a circular shape that receives the first buttons and the second buttons.
 4. The hard hat system of claim 1, wherein the first buttons of the plurality of first male couplers define a circular shape that is received in one of the apertures of the female couplers.
 5. The hard hat system of claim 4, wherein the second buttons of the plurality of second male couplers define a circular shape that is received in one of the apertures of the female couplers.
 6. The hard hat system of claim 1, wherein for each of the plurality of first male couplers the first button extends from a first arm that biases the first button through the aperture of a female coupler when the first male coupler is coupled to the respective female coupler, and for each of the plurality of second male couplers the second button extends from a second arm that biases the second button through the aperture of a female coupler when the second male coupler is coupled to the respective female coupler.
 7. The hard hat system of claim 1, wherein the plurality of female couplers comprises at least four female couplers.
 8. The hard hat system of claim 7, wherein the plurality of first male couplers comprises at least four first male couplers, and wherein the plurality of second male couplers comprises at least four second male couplers.
 9. The hard hat system of claim 8, wherein the plurality of female couplers are integrally molded with the shell.
 10. The hard hat system of claim 1, wherein there are twice as many first male couplers coupled to the straps as female couplers are coupled to the shell, wherein there are twice as many second male couplers coupled to the straps as female couplers are coupled to the shell.
 11. A hard hat system comprising: a hard hat comprising a shell formed from a rigid material, the shell comprising an external surface and an internal surface that defines a cavity sized to receive the head of a wearer; a plurality of female couplers coupled to the shell, each of the plurality of female couplers comprising a base and an aperture opposite the base; a plurality of straps configured to secure the shell to the head of the wearer; a plurality of first male couplers including a first button received within the aperture of a female coupler thereby coupling the first male coupler to the female coupler, the first button comprising a top surface facing away from the base of the respective female coupler, and a side surface that extends from the top surface at a first obtuse angle and that circumferentially surrounds the first button, wherein the first male coupler decouples from the female coupler when a first predetermined release force is applied that separates the first male coupler from the female coupler; and a plurality of second male couplers including a second button received within the aperture of a female coupler thereby coupling the second male coupler to the female coupler, each second button including a top surface facing away from the base of the respective female coupler, and a side surface that extends from the top surface at a second obtuse angle and that circumferentially surrounds the second button, wherein the second male coupler decouples from the female coupler when a second predetermined release force is applied that separates the second male coupler from the female coupler, wherein the second predetermined release force is at least 50 Newtons greater than the first predetermined release force; wherein each strap of the plurality of straps is directly coupled to one of the first male couplers and one of the second male couplers, one of which detachably couples to a female coupler of the plurality of female couplers at a time, thereby coupling the respective strap to the hard hat.
 12. The hard hat system of claim 11, wherein for each of the plurality of first male couplers the first button extends upward from an upper surface of a first arm that biases the first button through the aperture of a female coupler, wherein the side surface of the first button defines a third obtuse angle with respect to the upper surface of the first arm, and for each of the plurality of second male couplers the second button extends from a second arm that biases the second button through the aperture of a female coupler when the second male coupler is coupled to the respective female coupler, wherein the side surface of the second button defines a fourth obtuse angle with respect to the upper surface of the second arm.
 13. The hard hat system of claim 12, wherein the plurality of female couplers are integrally molded with the shell.
 14. The hard hat system of claim 11, wherein the plurality of female couplers are integrally molded with the shell.
 15. The hard hat system of claim 11, wherein the apertures of the plurality of female couplers define a circular shape that receives the first buttons and the second buttons.
 16. The hard hat system of claim 11, wherein the first buttons of the plurality of first male couplers define a circular shape that is received in one of the apertures of the female couplers, and wherein the second buttons of the plurality of second male couplers define a circular shape that is received in one of the apertures of the female couplers.
 17. The hard hat system of claim 11, wherein there are twice as many first male couplers coupled to the straps as female couplers are coupled to the shell.
 18. A strap system configured to secure a hard hat to the head of a wearer, the strap system comprising: a plurality of straps; a plurality of first male couplers including a first button received within an aperture of a female coupler coupled to a hard hat, thereby coupling the first male coupler to the female coupler, each first button comprising a top surface projected through the aperture of the female coupler and towards the head of the wearer, and a side surface that extends from the top surface at a first obtuse angle and that circumferentially surrounds the first button, wherein the first male coupler decouples from the female coupler when a first predetermined release force is applied that separates the first male coupler from the female coupler; and a plurality of second male couplers including a second button received within the aperture of a female coupler thereby coupling the second male coupler to the female coupler, each second button including a top surface facing towards the head of the wearer and a side surface that extends from the top surface at a second obtuse angle and that circumferentially surrounds the second button, wherein the second male coupler decouples from the female coupler when a second predetermined release force is applied that separates the second male coupler from the female coupler, wherein the second predetermined release force is at least 50 Newtons greater than the first predetermined release force; wherein each strap of the plurality of straps is directly coupled to one of the first male couplers and one of the second male couplers, one of which couples to a female coupler of the plurality of female couplers at a time, thereby coupling the respective strap to the hard hat.
 19. The strap system of claim 18, wherein the first buttons of the plurality of first male couplers define a circular shape that is received in one of the apertures of the female couplers, and wherein the second buttons of the plurality of second male couplers define a circular shape that is received in one of the apertures of the female couplers.
 20. The strap system of claim 18, wherein for each of the plurality of first male couplers the first button extends upward from an upper surface of a first arm that biases the first button through the aperture of a female coupler, wherein the side surface of the first button defines a third obtuse angle with respect to the upper surface of the first arm, and for each of the plurality of second male couplers the second button extends from a second arm that biases the second button through the aperture of a female coupler when the second male coupler is coupled to the respective female coupler, wherein the side surface of the second button defines a fourth obtuse angle with respect to the upper surface of the second arm. 